service repair manual

1. T13
T14
T17
TELEHANDLERS
Service Manual
Print N. 604.02.395.01 (III -- 2004)
THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.
Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid
potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:
WARNING -- Cautions directed to avoid improper repair interventions involving potential consequences for
the operator’s safety.
DANGER -- These warnings qualify specifically potential dangers for the safety of the operator or other
persons directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service
Organization of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the
recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own, for
the damages that may result.
Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national, regional
or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts
and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or
merchandized by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or
merchandized by the Factory, when failures are caused by the use of parts and/or components not approved by the
Factory.

2. Service manual
T13 -- T14 -- T17
TELESCOPIC HANDLERS
604.02.395.01 -- 03 -- 2004
GENERAL LIST OF CONTENTS
SECTION 00 -- GENERAL
Description Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General instructions 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety rules 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product identification 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental considerations 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance techniques 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 -- ENGINE
Description Page
Coding of engines of origin 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main specifications of engines 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General engine specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generalities 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of main mechanical components of the engines 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel and mechanical injection 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection assembly 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of engine transmission group from the vehicle 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine overhaul on bench 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the injectors 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve clearance 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing of setting 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing of injection pump 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical components 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tooling 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data --mounting – plays 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. 4 GENERAL LIST OF CONTENTS
604.02.395.01 -- 03 -- 2004
SECTION 21 -- POWERSHIFT GEARBOX
Description Page
Gearbox assembly 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler gear case assembly 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission and Hydraulic oil circuit diagrams 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modulation valve operation 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque converter and heat exchanger hydraulic oil circuit 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting procedures 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure testing clutch and high pressure circuit 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure testing torque converter and cooler circuit 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check points 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly instructions 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overhaul 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 25 -- FRONT AXLE
Description Page
Specifications 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel toe--in check 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component overhaul 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front axle removal procedure 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front axle overhaul 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle drive pinion bearing adjustment 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to install and adjust the axle drive pinion 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front drive shaft 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. GENERAL LIST OF CONTENTS 5
604.02.395.01 -- 03 -- 2004
SECTION 27 -- REAR AXLE
Description Page
Specifications 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation diagram 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component overhaul 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear axle removal procedure 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overhaul 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 33 -- BRAKES
Description Page
Power brakes 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking brake 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake disc adjustment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brakes disassembly 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 35 -- HYDRAULIC SYSTEM
Description Page
Technical data 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and operation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering system hydraulic circuit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering valve 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Telescopic boom hydraulic circuit 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic pump 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic scheme 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery side divider valve 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front loader controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power steering (OSPQ) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Telescopic boom distributor 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary controls distributor 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arms 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom removal 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Working platform 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure for the calibration of the personnel carrier platform electronic controller 47. . . . . . . . . . . . . . . . . . . . .
Special tools 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. 6 GENERAL LIST OF CONTENTS
604.02.395.01 -- 03 -- 2004
SECTION 55 -- ELECTRICAL SYSTEM
Description Page
Chapter 1 – Electrical system general
Electrical equipment specifications 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical system and fuse 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and instruments 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of the tip--over prevention system 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulb replacement 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting the electrical systems during charching or welding 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the machine using jump leads 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary wiring repair 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical system general fault finding 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Working platform 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2 – Circuit diagrams
List of connectors 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of components 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to use the circuit diagrams 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 1: Starting/Recharge/Warning lights/Indicator lights 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 2: Transmission 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 3: Wheel alignment/Hydraulic solenoids/Brake system 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 4: Arm control 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 5: Stabiliser 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 6: Lights/Windscreen wiper 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 7: Work lamps/Roof beacon light 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8: Tilting prevention system/Roof wiper 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 9: Sound system heating/Electric socket/Roof lamp 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 10: Air conditioner 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 3 -- Wiring list
Instrument panel wiring 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab wiring 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front wiring 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear wiring 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine wiring 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. SECTION 00 -- GENERAL 1
604.02.395.01 -- 03 -- 2004
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair interventions listed in this Manual must be performed exclusively by the Service
Network of the Manufacturer, complying strictly with the indications herein and using, when required, the
prescribed special tools.
Whoever performs service operations described herein without complying strictly with the instructions becomes
solely responsible for any consequential damage that could occur.
ADJUSTING SHIMS
For each adjustment select the adjusting shims, measuring them one by one with a micrometer and adding to
gether subsequently, the values measured. Do not rely on the measurement of the entire pack, that could be
wrong, or the nominal value indicated on each ring.
SEALS FOR ROTATING SHAFTS
For correct installation of the seals for rotating shafts, please comply with the following precautions:
-- prior to installation, keep the seals soaking for at least half an hour in the same oil they are going to seal;
-- clean thoroughly the shaft and make sure that its working face is undamaged;
-- direct the sealing lip toward the fluid; in the event the lip is of the hydro dynamic type, the grooves must be
directed so that, in relation to the rotating direction of the shaft, they tend to return the fluid toward the inside
of the sealing device;
-- smear the sealing lip with a film of lubricant (oil to be preferred to grease) and fill with grease the gap between
sealing lip and dust lip in twin lip seals;
-- insert the seal in its seat, pressing it with a punch with a flat face; never strike it with a hammer or mallet;
-- when pressing in the seal, make sure that it is inserted perpendicularly in relation to the seat and, once in
position, make sure that, when required, it contacts the shoulder;
-- to prevent the sealing lip of the seal being damaged by the shaft, insert appropriate protection during the
installation of the two parts.
“0--RING” TOROIDAL SEALS
Lubricate O--rings before inserting them in the relevant seats to prevent them becoming twisted and rolled during
installation, thus jeopardising their sealing capacity.
SELAING COMPOUNDS
Mating surface marked X must be smeared with a sealing compound recommended by the Manufacturer or an
adequate equivalent.
Prior to applying the compound, prepare the surfaces in the following manner:
-- remove all possible scaling with a metal brush;
-- degrease the surfaces thoroughly using the degreesing agent recommended by the Manufacturer or an
adequate equivalent.
BEARINGS
When installing bearings, it is recommended to:
-- warm them up to 80° – 90 °C (176 – 194 °F) before installing them on the relevant shafts;
-- cool them down before inserting them in the relevant seats with an outer fitting.
SPLIT PINS
When installing split pins, make sure that the cut is pointing in the direction of the load on the pin.
On the other hand, spiral elastic pins do not require any installation orientation.

7. 2 SECTION 00 -- GENERAL
604.02.395.01 -- 03 -- 2004
NOTES ON SPARE PARTS
Use genuine spare parts guaranteed by the Manufacturer only.
Genuine spare parts are the only ones ensuring the same quality, the same life and the same safety as the
originally mounted parts, since they are the same as the ones installed in production.
Only genuine parts from the manufacturer ensure this guarantee.
Orders for spare parts must include the following indications:
-- model of the vehicle (commercial designation) and serial number;
-- type and number of the engine;
-- part number for the item ordered, as provided by the “Microfiches” or the “Spare Part Catalogue”, on which
the order is based.
NOTES ON TOOLING
The tooling that the Manufacturer recommends and illustrates in this Manual is:
-- studied and designed specifically for servicing vehicles of this range;
-- required to ensure a reliable repair;
-- accurately developed and inspected to provide effective and long lasting working.
You are also reminded that correct tooling allows you to:
-- to operate under optimised technical conditions;
-- to achieve the best results;
-- to save time and effort;
-- to work in safer conditions.
WARNING
The wear limits provided for some items must be considered as recommended values, but not absolutelybinding.
The indications “front”, “rear, “right”, “left” refer to different parts as seen seating from in the operator’s seat
oriented in the normal travel direction of the vehicle.
HOW TO MOVE A VEHICLE WITHOUT BATTERIES
The cables of the external power supply must be connected exclusively to the respective terminals of the positive
and negative cables of the vehicle, using efficient clamps providing adequate and safe contact. In the event it
is necessary to check the operation of the electrical system of the vehicle, do it exclusively with the power supply
connected. At the end of the inspection, disconnect all actuators and deactivate the power supply before
disconnecting the cables.

8. SECTION 00 -- GENERAL 3
604.02.395.01 -- 03 -- 2004
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL
This alert symbol announces important messages involving your safety.
Read carefully the safety instructions listed and follow the precautions recommended
to avoid potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual with the following key words:
WARNING -- Cautions intended to avoid improper repair interventions involving
potential consequences for the safety of the personnel performing the repairs.
DANGER -- These warnings qualify specifically potential dangers for the safety of the
operator or other persons directly or indirectly involved.
AVOID ACCIDENTS
Most accidents, whether they occur in workshop, on
the farm, at home or on the road, are caused by the
failure of some individuals to follow simple and fun-
damental safety rules and precautions. For this rea-
son MOST ACCIDENTS CAN BE PREVENTED by
recognising the real cause and doing something
about it before the accident occurs.
Regardless of the care used in the design and con-
struction of any type of equipment, there are many
conditions that cannot be completely safeguarded
against without hindering reasonable accessibility
and efficient operation.
A careful operator is the best insurance against an
accident.
The complete observance of one simple rule would
prevent many serious accidents.
DANGER. Never attempt to clean, lubricate or main-
tain a machine while it is in motion.
SAFETY RULES
SAFETY RULES
◊ Read and heed all safety rules before any inter-
vention.
◊ Do not wear rings, wristwatches, jewellery, and
loose or hanging apparels, such as ties, torn
clothing, scarves, unbuttoned or unzipped
jackets that can catch on moving parts. Wear
proper safety equipment as recommended for
the job. Examples: hard hat, heavy gloves, ear
protection, safety glasses or goggles, reflector
vests, respirator. Consult your employer for spe-
cific safety equipment requirements.
◊ Do not perform any service operation on the
machine with a person seated in the operator’s
compartment, unless he is an authorised oper-
ator co--operating in the operation to be per-
formed.
◊ Never attempt to operate the machine or its tools
from any position other than seated in the oper-
ator’s seat.
◊ Never perform any intervention on the machine
with engine running unless this is prescribed.
◊ Cut--off the engine and make sure that all pres-
sures in the hydraulic systems are released
before removing caps, covers, valves etc.
◊ All service interventions must be performed with
the utmost care and attention.
◊ Shop and/or field service platforms or ladders
must be constructed and maintained in accord-
ance with local and national regulations.
◊ Disconnect the batteries and tag all controls to
signal that an intervention is in progress. Block
the machine and all equipment that must be
lifted.
◊ Do not check nor refill fuel tanks, as well as bat-
teries, nor use starting fluid while smoking or
near open flames since these fluids are flam-
mable.
◊ Brakes are inactive when manually released for
service interventions. Under such circum-
stances it is necessary to maintain the control of
the machine using appropriate blocks or similar
devices.
◊ The fuel--filling nozzle must be kept constantly
inside the filling neck. Keep this contact from the
beginning to the end of the fuelling operation to
avoid the possibility that sparks due to static
electricity are generated.
◊ Use only designated towing or attaching points.
Use care in making attachments. Make sure pins
and/or locks are secure before pulling. Stay clear
of drawbars, cables or chains under load.
◊ To move a disabled machine, use a trailer or a
low--boy, if available.

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10. 4 SECTION 00 -- GENERAL
604.02.395.01 -- 03 -- 2004
◊ To load/unload a machine from transporter,
choose a level surface ensuring firm support to
the wheels of truck or trailer. Anchor the machine
securely to the bed of truck or trailer and block
wheels or tracks with appropriate wedges.
◊ Use only approved grounded auxiliary power
sources for heaters, chargers, pumps and simi-
lar equipment to reduce the hazards of electrical
shocks.
◊ Lift and handle heavy parts with a lifting device
of proper capacity.
◊ Beware of bystanders.
◊ Never pour gasoline or diesel fuel into open,
wide and low containers.
◊ Never use gasoline, solvent or other flammable
fluid to clean parts. Use exclusively qualified,
non--flammable, non--toxic commercial sol-
vents.
◊ When using compressed air for cleaning parts,
use safety glasses with side shields or goggles.
◊ Limit pressure to 2.1 bar, in accordance with
local and national regulations.
◊ Do not run the engine in closed areas without
proper ventilation to remove deadly exhaust
fumes.
◊ Do not smoke or permit any open flames orspark
near when re--fuelling or handling flammable
materials.
◊ Do not use an open flame as a light source to
look for leaks or for inspection anywhere on the
machine.
◊ Move with extreme care when working under the
machine, its attachments and or on or near
them. Always wear protective safety equipment
as required, such as hard hat, goggles, safety
shoes, ear plugs.
◊ When performing operations requiring runningof
the engine, have a qualified operator in the oper-
ator’s seat at all times with the mechanic on
sight. Place the transmission in neutral and set
the brakes and safety lock.
◊ For field service, move machine to level ground,
if possible, and block it. If work on an incline is
absolutely necessary, first block machine and its
attachments securely, than move it to level
ground as soon as possible with a certain margin
of safety.
◊ Do not trust worn and /or kinked chains and
cables: do not use them for lifting or pulling oper-
ations. To handle them, always use heavy
gloves.
◊ Be sure chains and cables are anchored and the
anchor points are strong enough to handle the
expected load. Keep exposed personnel clear of
anchor points and cables or chains. No
bystanders are allowed near the hooking points,
chains or cables.
◊ Keep the area where maintenance operations
are performed CLEAN and DRY. Eliminate
immediately all water and oil spillages.
◊ Do not pile up oily or greasy rags; they represent
a fire hazard. Store in a closed metal container.
Before starting machine, check, adjust and lock
the operator’s seat for maximum comfort and
control of the machine. Be sure exposed
personnel in the area of operation are clear of the
machine before moving it or its attachments.
Sound the horn.
◊ Do not carry loose objects in pockets that might
fall unnoticed into open compartments.
◊ Wear proper protective equipment such as
safety goggles or safety glasses with side
shields, hard hat, safety shoes, heavy gloves
when metal or other particles are apt to fly or fall.
◊ Wear welders protective equipment such as
dark safety glasses, helmets, protective cloth-
ing, gloves and safety shoes, when welding or
burning. Wear dark safety glasses near welding
zones. DO NOT LOOK AT ARC WITHOUT
PROPER EYE PROTECTION.
◊ Steel cables are frayed after prolonged use;
always wear appropriate protections (heavy
gloves, goggles etc.).
◊ Handle all parts carefully. Keep hands and
fingers away from structures, gears or moving
parts. Use and wear always the appropriate
protections, such as safety goggles, gloves and
safety shoes.

11. SECTION 00 -- GENERAL 5
604.02.395.01 -- 03 -- 2004
STARTING
◊ Do not run the engine in closed areas without
proper ventilation to remove deadly exhaust
fumes.
◊ Do not place head, body, limbs, feet, hands or
fingers, near rotating fans or belts. Be especially
alert near pusher fans.
ENGINE
◊ Loosen the radiator cap very slowly, to release
pressure from the system, before removing it. All
coolant level top--ups must be performed with
engine inoperative or at low idle, if warm
◊ Do not run engine when refuelling and use care
if the engine is hot due to the increased possibil-
ity of a fire if fuel is spilled.
◊ Never attempt to check or adjust fan belts when
engine is running. Do not adjust engine fuel
pump when machine is moving.
◊ Never lubricate the machine with engine run-
ning.
ELECTRICAL SYSTEM
◊ Should booster batteries be used, remember to
connect both ends of the booster cables in the
proper manner (+) with (+) and (--) with (--). Avoid
short--circuits of the terminals. Follow thoroughly
the instructions of this Manual.
Avoid short circuiting the terminals. BATTERY
GAS IS HIGHLY FLAMMABLE. Leave battery
box open to improve ventilation when recharging
batteries. Never check charge by placing metal
objects across the posts. Keep sparks or open
flames away from batteries. Do not smoke near
battery to guard against the possibility of causing
an explosion.
◊ Before any intervention, make sure that there
are no fuel or electrolyte leakages; eliminate
them before proceeding with further work.
◊ When recharging batteries in closed ambient,
make sure that there is appropriate ventilation to
prevent possible accidental explosions due to
the accumulation of gases generated during the
recharge.
◊ Before any intervention, make sure that the main
switch is OFF.
HYDRAULIC SYSTEM
◊ Fluid escaping under pressure from a very small
hole can be almost invisible and can have suffi-
cient force to penetrate the skin. Use a piece of
cardboard or wood to search for suspected pres-
sure leaks. do not use hands. If injured by escap-
ing fluid, see a doctor at once. Serious infection
or reaction can develop if proper medical treat-
ment is not administered immediately.
◊ In case pressures must be measured, use
instruments of adequate capacity. Always follow
the recommended procedures.
WHEELS AND TYRES
◊ Make sure that the inflation pressure of the tyres
is according to the specifications issued by the
Manufacturer and check it periodically.
◊ Should the pressure be changed, stand on the
side of the tyre at a safe distance.
◊ Pressure check operations must be performed
with unloaded machine and cold tyres. Never
use reconditioned tyre rims, since eventual
weldings, heat--treatments or repairs not per-
formed correctly can weaken the wheel, thus
causing subsequent damages or dangers.
◊ Do not perform torch cutting or welding oper-
ations on rims with inflated tyres installed.
◊ Before operating on tyres, block all wheels, front
and rear. After jacking the machine, block it with
stands according to current safety rules and
regulations.
◊ Before removing objects from the tyre tread,
deflate it.
◊ Never inflate tyres with flammable gas;
explosions and serious bodily injuries may
result.
REMOVALS AND INSTALLATIONS
◊ Lift and handle all heavy parts with lifting devices
of adequate capacity. Make sue that the parts
are attached to lifting devices are properly
slinged. Use the lifting eyes provided. Beware of
persons in the vicinity.
◊ Handle all parts carefully. Keep hands and
fingers away from structures, gears or moving
parts. Use and wear always the appropriate
protections, such s goggles, gloves and safety
shoes.
◊ Prevent chains and cables from kinking. To
handle them, always use heavy gloves.

12. 6 SECTION 00 -- GENERAL
604.02.395.01 -- 03 -- 2004
PRODUCT IDENTIFICATION
The Telehandler and its main components are identi-
fied by various numbers and letters providing its
identification by the Service network. The following
information gives the location of the identification
plates, of the numbers stamped on the machine and
various examples of what can be found on the
machine.
VEHICLE SERIAL NUMBER
The serial number is stamped on the front part of the
machine, on the upper side of the main frame, right
side. Example: *ZEFK1740AXXXXXXXX*
NOTE: The serial number and the identification
number of the components can be requested by the
Dealer when Spare Parts are ordered or interven-
tions are required. These numbers are also required
as help in identifying the machine in theevent of theft.
Keep them in a safe place.
TH100040
1
VEHICLE IDENTIFICATION PLATES
The vehicle identification plate is located on the left
side of the seat location. Record here below the data
for your machine.
TECHNICAL TYPE/MODEL
SERIAL NO. OF VEHICLE
YEAR
TH001050
ϒ
2
IDENTIFICATION OF ENGINE
The identification data of the engine are on the left
side of the engine cylinder block. Please record here
below these data for easier consultation, when
required.
MODEL NO.
SERIAL NO.
DATE CODE
TH001029
3